WO2014065847A2

WO2014065847A2 - Multi-function media embellishing die

Info

Publication number: WO2014065847A2
Application number: PCT/US2013/023158
Authority: WO
Inventors: James Jeffery CARON
Original assignee: SPELLBINDERS PAPER ARTS LLC
Current assignee: SPELLBINDERS PAPER ARTS LLC
Priority date: 2012-10-22
Filing date: 2013-01-25
Publication date: 2014-05-01
Anticipated expiration: 2015-04-22
Also published as: WO2014065847A3

Abstract

A multi-function media embellishing die and a system and method of embellishing media with the die is provided. The die includes a body having a media abutment surface, a die blade extending from the media abutment surface and a punch element having a protruding member extending from the media abutment surface and terminating in a substantially flat raised surface. The cut edge and the substantially flat raised surface can be disposed about the same height above the media abutment surface. The media embellishing die can include an embossing element having a protruding member extending from the media abutment surface and terminating in a substantially flat raised surface disposed at about the same height above the media abutment surface as the cut edge. A system for embellishing media includes the die and a press for pressing media against the die to embellish the media.

Description

MULTI-FUNCTION MEDIA EMBELLISHING DIE

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 61/716,833 filed October 22, 2012.

BACKGROUND

[0002] The present invention relates to a system and method of embellishing media, and more particularly to a media embellishing die.

[0003] The papercraft and scrapbook industry has become widely popular seeing explosive growth in recent years. Many people have taken up the hobby of keeping mementos and photos in scrapbooks and they wish to personalize their collections using embellished media, such as die cut and/or embossed paper and the like.

[0004] Typical known systems for embellishing media use a press for pressing the media against a die to embellish the media. These systems use a die having an embellishing surface for embellishing the media during pressing. The embellishing surface may be a die cut blade for die cutting the media. The embellishing surface may be a recess or protrusion for embossing the media. It is desirable to provide a die having one or more punch elements in combination with other features for embellishing media in a variety of different ways.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The invention may take form in certain components and structures, preferred embodiments of which will be illustrated in the accompanying drawings wherein:

[0005] Fig. 1 is a sectional elevational view illustrating a media embellishing die in accordance with the invention;

[0006] Fig. 2 is a sectional elevational view of the media

l embellishing die shown in Fig. 1 ;

[0007] Fig. 3 is a sectional elevational view of the media embellishing die shown in Fig. 1 and embellished media formed by same;

[0008] Fig. 4 is a top view of another embodiment of the embellishing die in accordance with the invention;

[0009] Fig. 5 is a sectional elevational view of the embellishing die shown in Fig. 4;

[0010] Fig. 6 is a sectional elevational view of the embellishing die shown in Fig. 4 and embellished media formed by same;

[0011] Fig. 7 is a top view of another embodiment of the embellishing die in accordance with the invention;

[0012] Fig. 8 is a block diagram illustrating a system for embellishing media in accordance with the invention; and

[0013] Fig. 9 is a block diagram illustrating another embodiment of a system for embellishing media in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0014] It is to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific examples and characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0015] The term "embellish" as used herein refers to altering the appearance of media. Media can be embellished by cutting, such as for example by die cutting with a dies, and/or by embossing and/or by stenciling. The term "embossing" as used hereinafter refers to forming a three dimensional impression, also referred to as an embossment, of a portion of a die in the media. The term "debossing" as used hereinafter refers to forming a three dimensional impression, also referred to as a debossment, of a portion of a die in the media extending in a direction opposite the embossment. The embossing and/or debossing is dry embossing and/or debossing which does not use heat. The media can be sheet media a material suitable for embellishing with a die including, but not limited to, paper, card stock, cardboard, metal, such as for example metal foil or other thin metals, and plastic, among others. The die(s) described herein can be referred to as one-piece dies which are different than a two-piece die having complementary male and female die pieces.

[0016] Referring to Figs. 1-3, a media embellishing die is shown generally at 10a for embellishing media 12, which in the illustrated embodiment is sheet media. The die 0a includes a body 14 having a first side 16, and a second side 18 disposed opposite the first side. The second side 18 includes a generally flat surface 19. The body 14 can be a one-piece body formed of a unitary piece of material as shown in figures. The body 14 is generally hard and can be formed of metal, including but not limited to steel, such as hard steel, spring steel, 1065-1075 steel, or other materials hard enough to retain, in operating condition, one or more embellishing surfaces formed thereon after multiple pressings. The die 10a can be formed of an etchable material, such as a chemically etchable material, as is explained in further detail below. The body 14 is generally flat, apart from protrusions extending therefrom or recesses formed therein as described below. The body 14 is about 0.010 inches to about 0.060 inches thick, though other thicknesses suitable for pressing may be used. In one example, which should not be considered limiting, the body 14 is about 0.020 inches to about 0.050 inches thick. In another example, which should not be considered limiting, the body 14 is about 0.030 inches to about 0.040 inches thick.

[0017] The die body 14 includes a first surface 20 disposed on the first side 16 for abutting and supporting a first side 22 of the media 12 as press forces push the media against the die 10a during pressing. The first surface 20, also referred to as the media abutment surface 20, is generally flat or planar, and is generally parallel to the surface 19 of the second side 18.

[0018] The die body 14 also includes a die blade, referred to generally at 30, extending from the media abutment surface 20 and terminating in a die blade edge 32, also referred to as a cut edge. The blade edge 32 extends to a height H above the media abutment surface 20. The die blade 30 can be formed to have a generally triangular cross sectional shape providing a comparatively sharp blade edge 32 to reduce the press forces needed to die cut the media 12 as it is pressed against the die blade. It should be appreciated that, for a particular media 12 of a particular thickness, an inverse relationship exists between the sharpness of the embellishing surface 34 and the amount of force needed for cutting it, such that a sharper edge requires lower press forces. Further, the amount of force applied to the media 12 and die 10a by the press during pressing can be varied, as described below.

[0019] In one example, the die blade 30 extends along the media abutment surface 20 in a continuous manner, as shown at 30a in Figs. 4 and 7, to circumscribe a predetermined, closed loop shape without end portions, such as a circle, square, or any other suitable predetermined shape which is desired to be cut into the media 12. Pressing the media against the cut edge 32 of this die blade 30a cuts out the predetermined shape from the media 12. Alternatively, the die blade 30 can extend along the media abutment surface 20 such that it has end portions, as shown at 30b in Figs. 4 and 7. Pressing the media against the cut edge 32 of this die blade 30b cuts the media 12 in the shape that the die blade and cut edge forms as it extends along the media abutment surface 20. In one example, the die 10a includes a plurality of die blades 30, each extending from the media abutment surface 20 and terminating in a respective cut edge 32. The plurality of cut edges 32 are each disposed at the same height H above the media abutment surface 20. For any particular die, H can have a variance of about 0.002 inches to about 0.012 inches, and more preferably a variance of about 0.002 inches to about 0.006 inches.

[0020] The die body 14 also includes a punch element 40 having a protruding member 41 extending from the media abutment surface 20 and terminating in a substantially flat raised surface 42. The substantially flat raised surface 42 may not be perfectly flat and can vary by small amounts due to limitations in the manufacturing process. Non-limiting examples of the variation in flatness of the substantially flat raised surface 42 can be about 0.001 inches to about 0.003 inches. [0021] The substantially flat raised surface 42 is generally planar and generally parallel to the media abutment surface 20. The substantially flat raised surface 42 is disposed at a height H above the media abutment surface 20. For a die 10 having a thickness of about 0.032 inches, H can be about 0.010 inches to about 0.025 inches. For a die 10 having a thickness of about 0.062 inches, H can be about 0.008 inches to about 0.050 inches. For any particular die, H can have a variance of about 0.002 inches to about 0.012 inches, and more preferably a variance of about 0.002 inches to about 0.006 inches.

[0022] In one non-limiting example, the substantially flat raised surface 42 of the punch element 40 has surface area Ai that can be about 80.0x10^"6 in² to about 0.3 in². In another example, surface area Ai can be about 30.0x10^"5 in² to about 0.2 in², and it should be appreciated that these are examples are provided for the purposes of illustrating the dimension of the surface area of the terminated end 42 of the punch element 40 protruding member 41.

[0023] The die body 14 can include a plurality of punch elements, referred to generally at 40, having respective protruding members 41 extending from the media abutment surface 20 each terminating in a substantially flat raised surface, referred to generally at 42. The plurality of substantially flat raised surfaces 42 are each disposed at the same height H above the media abutment surface 20. The plurality of substantially flat raised surfaces 42 can have the same shape, when viewed in a top, or plan view. Alternatively, one or more of the plurality of substantially flat raised surfaces 42 can have different shapes, when viewed in a top, or plan view. The surface areas of the substantially flat raised surfaces 42, referred to generally as Ai, can be the same. In other examples the surface areas Ai of the substantially flat raised surfaces 42 can be different. However, the surface areas Ai of each of the punch element raised surfaces is about 80.0x10^"6 in² to about 0.3 in², in one example, and about 30.0x10^"5 in² to about 0.2 in² in another example. The one or more punch element substantially flat raised surfaces 42 are generally planar and generally parallel to each other and to the media abutment surface 20. [0024] The die body 14 can also include one or more embossing elements 50 each having a respective protruding member 51 extending from the media abutment surface 20 and terminating in respective substantially flat raised surfaces 52. The substantially flat raised surfaces 52 may not be perfectly flat and can vary by small amounts due to limitations in the manufacturing process. Non-limiting examples of the variation in flatness of the substantially flat raised surface 52 can be about 0.001 inches to about 0.003 inches.

[0025] The one or more embossing element substantially flat raised surfaces 52 are generally planar and generally parallel to each other and to the media abutment surface 20. These one or more surfaces 52 are all disposed at about the same height H above the media abutment surface 20, which is the same height as the one or more punch element substantially flat raised surfaces 42 described above. For any particular die, H can have a variance of about 0.002 inches to about 0.012 inches, and more preferably a variance of about 0.002 inches to about 0.006 inches.

[0026] The one or more substantially flat raised surfaces 52 can have the same shape, when viewed in a top, or plan view. Alternatively, one or more of these substantially flat raised surfaces 52 can have different shapes, when viewed in a top, or plan view. The surface areas of the one or more embossing element substantially flat raised surfaces 52, referred to generally as A₂, can be the same. In other examples, the surface areas A₂ of one or more of the embossing element substantially flat raised surfaces 52 can be different. However, the surface areas A₂ of each of the substantially flat raised surfaces 52 are each greater than about 0.3 in², and in another example, greater than about 0.35 in², so as to emboss and not punch through a location in the media 12 during one or more pressings, as described in further detail below.

[0027] Referring now to Figs. 4-6, another example of the die 10b can include one or more apertures 60, which can also be referred to as through holes or windows, formed in the media abutment surface 20 and extending through the die body 14. Each aperture 60 includes an aperture wall 62 extending through the die body 14, from the first side 16 to the second side 18. The aperture wall 62 defines the shape of the aperture 60 and cooperates with the media abutment surface 20 such that the media 12 is pressed against the media abutment surface and into the aperture 60 to form a debossment in the media having a shape similar to the shape of the aperture, as discussed in further detail below. In one example, the die 10b also includes one or more of the die blades 30 and punch elements 40 described above. In another example, the die 10b can also include one or more of the embossing elements 50 described above.

[0028] The die shown in Fig. 4 includes a single aperture 60 having an octagonal shape formed in the media abutment surface 20, however, it should be appreciated this die is simplified for the purposes of illustration. Referring to Fig. 7, another example of the die 10c includes a plurality of apertures 60 extending through the die body 14. One or more of the apertures 60 can have similar shapes, or different shapes, which define a predetermined embossing pattern for forming an embossed impression in the form of one or more respective protrusions in the media 12 during pressing as shall be described in further detail below. The embossed impression formed by the one or more apertures 60 extend in the opposite direction as the one or more embossments 76 formed by the one or more embossing elements 50, and can therefore be referred to as debossments 78 as shown in Fig. 6.

[0029] The die blade, referred to generally in these examples at 30, extends along the media abutment surface 20 to form a predetermined pattern which is to be cut into the media 12 as the media is pressed against the die, the media abutment surface and the die blade cut edge 32. In one example which should not be considered limiting, the die blade 30 shown in Fig. 4 forms an octagonal pattern. However, it should be appreciated this pattern has been simplified for the purposes of example, and that the die blade 30 can traverse the media abutment surface 20 in any suitable predetermined pattern, as shown in Fig. 7 for example, for forming a corresponding cut 72 in the media 12. In one non-limiting example, the die blade 30a can extend along the media abutment surface 20 in a continuous, closed loop manner to die cut a predetermined shape out of the media, as shown in Figs 4 and 7. In another non-limiting example, the die blade 30b can include one or more non-continuous die blades, which do not form closed loops, extending from the media abutment surface 20 and terminating in respective die blade cut edges 32 traversing the media abutment surface in any suitable predetermined pattern so as to form one or more corresponding cuts in the media as desired, as shown in Figs 4 and 7.

[0030] Referring to Fig. 8, a system for embellishing media 12 is shown generally at 100a. The system 100a includes the embellishing die 10a, 10b, or 10c, as described above, referred to hereafter generally as die 10, and a press 116 having press members 118 for applying press forces, shown by arrows 120, during pressing. The press 116 can be a roller press having rollers for press members 118, or another press suitable for pressing the media 12 against the embellishing die 10 while keeping the die and media in a general planar orientation to embellish the media. During pressing, while applying press forces 120, the press members 118 can be maintained a fixed distance apart from each other. For example, the roller press rollers 118 are spaced apart by a fixed distance and supported for rotation at each end by bearings (not shown) which do not allow the rollers to move away from each other during pressing. As an example, which should not be considered limiting, the outer surfaces of the press rollers 118 can be disposed about 0.700 inches to about 0.750 inches apart.

[0031] The system 100 can further include a rigid platen plate assembly 130 for transferring press forces 120 from the press members 118 to the media 12 and die 10 for pressing the media and die together during pressing. The platen plate assembly 130 can also distribute the press forces 120 when press members 1 18 that are not generally planar, such as roller press members, are used in the press 116. In one example, the platen plate assembly 130 includes a first flat member 132 and a second flat member 134, used in a spaced apart relationship with the die and media disposed therebetween as illustrated. The first and second flat members 132 and 134 are generally planar members, formed of rigid, somewhat resilient materials, such as for example, high density polyethylene, or polystyrene, among others. The first and second flat members 132, 134 can be formed of the same material having the same hardness, or different materials (or different compositions of the same material) having different hardnesses. The first and second flat members 132, 134 can have the same dimensions, such as for example the same thicknesses. In another example, they can have different dimensions, such as different thicknesses. In another example, the platen plate assembly 130 can include only one of the flat members, 132 or 134.

[0032] The system 100 can further include an optional spacer 121 disposed between the press members 1 18 for transferring press forces

120 from the press members to the media 12 and the die 10. The spacer

121 can abut the die 10 or the media 12. Different spacers 121 having different physical properties can be used in the press in which the press members 118 are disposed, or moved into, a fixed distance apart to vary the press force characteristics applied to the media 12 and die 10 by the press members 118 during pressing. The spacer 121 can be formed having a wide range of hardnesses to accomplish different functions during pressing as described below. Further, different spacers 121 , each having a different thickness can be used to vary the magnitude of the press forces 120 applied to the media 12 and die 10 by press members 118 which are disposed a fixed distance apart, or reach a fixed distance apart, during pressing. It should be appreciated the press forces applied during pressing should have a magnitude falling within a range which depends at least on the type and thickness of the media, the dimensional characteristics of the embellishing surface 34 and the type of embellishment desired.

[0033] In one example, the spacer 121 can be a rigid spacer 122 formed of a rigid material, examples which should not be considered limiting, include high density polyethylene and polystyrene. The rigid spacer 122 can be slightly pliable or resilient to be capable of regularly coming into contact with the cut edge 32 without prematurely dulling it. The rigid spacer 122 can have a hardness ranging from about D60 Shore to a Rockwell C hardness of about 60. In the example provided herein, the rigid spacer 122 can have a thickness of about 0.062 inches, though other thicknesses can be used in accordance with the dimensions of the press member 118 spacing and platen plate thicknesses and the thicknesses of the media 12 and die 10.

[0034] The rigid spacer 122 can be placed between a platen plate 130 and the die 10 or media 12, or between a press member 118 and the die or media, for die cutting the media with the die blade 30 and punching the media using the punch element is a block diagram illustrating a system for embellishing media in accordance with the invention. In one example, which is not considered to be limiting, a first pressing operation can be performing by forming a stack, also referred to as a "sandwich" 136, which is pressed between the press members 118. The sandwich 136 is formed by placing the die 10 on the platen plate first member 132, with the surface 19 of the second side 18 the disposed against the first member. The media 12 is then placed on against the first side 18 of the die and a spacer 122 is placed on top of the media. A second member 134 of the platen plate 130 can be placed on top of the space 122. Alternatively, the sandwich 136 can be formed using only one of the platen plate members 132 and a rigid spacer 122. In the example provided herein, the media can be about 0.003 inches to about 0.013 inches thick. In other examples, media having other thicknesses can be used. The sandwich 136 is then held approximately level and pushed between the rollers 118 as they are turned. The turning rollers 118 grasp the sandwich 136 and pull it between them as press forces 120 are applied pressing the media 12 against the die 10 in a first pressing, also referred to as a first press operation.

[0035] Using the die 10 having one or more die blades 30 and one or more punch elements 40, the media 12 is pressed against the one or more die blades 30 and die cut by the corresponding one or more die blade cut edges 32. As mentioned above, the die 10 can include die blades 30a which form one or more closed loop shapes and/or die blades 30b which form one or more non-closed loop shapes which are cut in the media.

[0036] During the first pressing, the media 12 is also pressed against the one or more punch elements 40 and the one or more embossing elements 50. As the media 12 is pressed against the one or more embossing elements 50, the one or more respective embossing element substantially flat raised surfaces 52 create embossed impressions(s) also referred to as embossment(s) 76 in the media. As the media 12 is pressed against the one or more punch element 40, the one or more respective punch element substantially flat raised surfaces 42 punch through the media to form one or more respective punched apertures 74 in the media in the shape(s) of the corresponding raised surfaces 42.

[0037] In another example, the one or more punch elements 40 do not punch through the media 12 in the first pressing, creating an embossment. The sandwich 136 is then pressed in the press 116 in a second pressing, so that the one or more punch element raised surfaces 42 punch through the media 12 at the same location(s) of the embossment(s) which they created in the previous pressing. The one or more embossing element raised surfaces 52 are pressed into the embossments 76 made previously, in the first pressing, without punching through the media thereby leaving the embossments 76 in a similar condition as the first, or previous, pressing. In one example, the same elements of the sandwich 136 can be used in the first and second pressings to generate the same press forces in the first and second pressing. In another example, different elements of the sandwich 136, such as for example different spacers 122, can be used to generate different press forces in the first and second pressing.

[0038] In another example, using a die 10b having one or more die blades 30, one or more punch elements 40, and one or more apertures 60 can be in the sandwich 136 described above to embellish the media 12. In this example, the one or more die blades 30 die cut the media 72, the one or more punch elements 40 punch the media to form corresponding one or more apertures 74 having shapes corresponding to the respective raised surfaces 42 of the respective punch elements, and the one or more apertures 60 form debossment(s) 78 in the media in the shape(s) of the aperture(s).

[0039] In another example, a die 10b, 10c having one or more die blades 30, one or more punch elements 40, one or more embossing elements 50, and one or more apertures 60 are be used in the sandwich 136 described above to embellish the media 12. This die 10b, 10c embellishes the media 12 in a similar manner as the previous example, while the one or more embossing elements 50 also form one or more embossments 78 having shapes similar to the one or more embossing element raised surfaces 52.

[0040] The spacer 121 can also be an elastomeric embossing pad 123 formed of a resilient or elastic material which deforms when the press forces 120 are applied during pressing and returns to its original shape when the press forces are removed. In the example provided herein, the embossing pad 123 can have a thickness of about 0.06 inches, though other thicknesses can be used in accordance with the dimensions of the press member 118 spacing, platen plate thicknesses, and the thicknesses of the media 12 and die 10.

[0041] Different press force characteristics can be generated during pressing by using different spacers 121 in the form of different elastomeric embossing pads 123 having different preselected hardnesses when pressing the media and the embellishing die 10 in the press 116a, 116b. The press force 120 can be adjusted by using an elastomeric pad having a higher hardness for generating greater press forces and a lower hardness for generating lower press forces. It has been found that elastomeric pads having a hardness on the Shore hardness scale ranging from about A20 to about A80, and more preferably ranging from about A40 to about A65, can be used.

[0042] The apertured die 10b, 10c can also be used as a stencil for embellishing the media 12, also referred to a stenciling. Material 70, including but not limited to chalk, ink, paint, glue, and glitter, among others, can be applied through the aperture 60 to the media 12 as it lay against the die 10b, 10c. In one example, which should not be considered limiting, the material 62 is applied through the aperture 24 to the debossment(s) extending into the aperture(s) 60 after pressing. This can be done after a single press operation, or two or more press operations, are performed with the same die 10b, 10c. The die first side 16 or second side 18 together with the aperture(s) 60 and aperture wall(s) 62 act as a stencil confining the application of the material 70 to the media in the shape defined by the aperture. Therefore, one die 10b, 10c as described herein, can be used to embellish the media 12 in several different ways. The die can die cut the media, punch the media, emboss the media, deboss the media, and stencil the media, depending on which features described above are included on the die.

[0043] Referring to Fig. 9, another example of a system for embellishing media 12 is shown generally at 100b. The system 100b includes the embellishing die 10, the sandwich 136, and a platen press 116b having generally flat press members 118 for applying press forces, shown by arrows 120, during pressing. During pressing, while applying press forces 120, the press members 118 are moved into a fixed distance apart from each other.

[0044] The dies 10 described herein can be formed by chemically etching the surfaces of a die blank to remove portions of the die blank so at to etch down to the media abutment surface 20. In one non-limiting example, the die blank is formed of a hard, chemically etchable material, and more particularly, a 1075 specialty strip steel having a Rockwell hardness of about 44 to about 48. A resist is applied to one or both sides of the die blank. The resist prevents the portions of the die blank disposed beneath it from being removed by the etching substance during etching. The resist can be a photo sensitive polymer film, such as Riston^® by Dupont, or other suitable resists. A mask is then applied over the resist. The mask has light admitting portions and light blocking portions. The light admitting portions are disposed on top of the sections of the die blank that will not be etched, and the light blocking portions are disposed on top of the sections that will be etched. The light admitting portions define a shape similar to the desired shape of the die blade(s) 30, punch element(s) 40 and embossing element(s) 50 will form traversing across the die first side 16.

[0045] A second mask, can be applied over the resist on the die blank second side. The light blocking portions are disposed on top of sections that will be etched, such as for example, portions corresponding to the desired shape of the aperture(s) 60 to be etched into the die blank second side. Light, such as for example Ultra-Violet (UV) light, is then directed towards the masks traveling through the light admitting portions and striking the photoresist and setting or curing them. Next, the portions of the resist which are not set are washed away, during a step referred to as developing, leaving only the portions that are set.

[0046] The die is then etched using a chemical etchant, such as for example, Ferric Chloride 38 Baume, from Phibro-Tech, Inc., or other suitable etchants. One side of the die blank can be etched in this manner. Alternatively, both sides of the die blank can be exposed to the etching substance to simultaneously etch the die. The etchant etches the first and/or second sides removing portions of die blank material corresponding to the portions not covered by the resist.

[0047] It has been found that the die blade 30 can be made having a sharper blade edge by flash etching the entire first side 14 of the die 10 including the die blade. After the first etching step is performed as described above, any remaining resist is removed. The entire first side 14 is then flash etched by exposing it to the etchant for a time period of about 1 minute to about 3 minutes.

[0048] The invention has been described with reference to preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding specification. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims

What is claimed is:

1. A one-piece media embellishing die for embellishing sheet media in a press comprising:

a body having a media abutment surface, a die blade extending from the media abutment surface and terminating in a cut edge, and a punch element having a protruding member extending from the media abutment surface and terminating in a substantially flat raised surface, wherein the cut edge and the substantially flat raised surface are about the same height above the media abutment surface.

2. The one-piece media embellishing die of claim 1 further comprising;

an embossing element having a protruding member extending from the media abutment surface and terminating in a substantially flat raised surface disposed at about the same height above the media abutment surface as the cut edge.

3. The one-piece media embellishing die of claim 2 wherein the punch element substantially flat raised surface has a surface area Ai, and the embossing element substantially flat raised surface has a surface area A₂, wherein A₂ > Ai.

4. The one-piece media embossing die of claim 1 wherein the body is formed of a unitary piece of material.

5. The one-piece media embellishing die of claim 1 further comprising an aperture formed in the media abutment surface having an aperture wall extending through the body.

6. The one-piece media embellishing die of claim 5 further comprising a plurality of apertures formed in the media abutment surface each having a respective aperture wall extending through the body.

7. The one-piece media embellishing die of claim 1 further comprising a plurality of punch elements, each of the plurality of punch elements having a respective protruding member extending from the media abutment surface and terminating in a substantially flat raised surface, wherein the cut edge and the substantially flat raised surfaces are about the same height above the media abutment surface.

8. The one-piece media embellishing die of claim 1 further comprising:

a plurality of punch elements, each of the plurality of punch elements having a respective protruding member extending from the media abutment surface and terminating in a substantially flat raised surface,

a plurality of die blades, each of the plurality of die blades extending from the media abutment surface and terminating in a respective cut edge, wherein the cut edges and the substantially flat raised surfaces are about the same height above the media abutment surface.

9. The one-piece media embellishing die of claim 1 further comprising

an embossing element having a protruding member extending from the media abutment surface and terminating in a substantially flat raised surface disposed at about the same height above the media abutment surface as the cut edge; and

an aperture formed in the media abutment surface having an aperture wall extending through the die;

10. The one-piece media embellishing die of claim 1 further comprising:

a plurality of punch elements, each of the plurality of punch elements having a respective protruding member extending from the media abutment surface and terminating in a substantially flat raised surface, wherein the cut edge and the substantially flat raised surfaces are about the same height above the media abutment surface; and

a plurality of apertures formed in the media abutment surface each having a respective aperture wall extending through the die.

11. The one-piece media embellishing die of claim 1 further comprising:

a press having a press member pressing the media against the die media abutment surface and against the blade and against the punch element.

12. A one-piece dry embossing die for embossing and die cutting sheet media in a press comprising:

a one-piece body having a media abutment surface, a die blade extending from the media abutment surface and terminating in a cut edge, a punch element having a protruding member extending from the media abutment surface and terminating in a substantially flat surface having a surface area Ai, and an embossing element having a protruding member extending from the media abutment surface and terminating in a substantially flat surface having a surface area A₂, wherein A₂ > Ai.

13. The one-piece dry embossing die of claim 12 wherein area Ai is about 80.0x10^"6 in² to about 0.3 in².

14. The one-piece dry embossing die of claim 13 wherein area Ai is about 30.0x10^"5 in² to about 0.2 in².

15. The one-piece dry embossing die of claim 12 wherein area A₂ is greater than about 0.3 in².

16. The one-piece dry embossing die of claim 15 wherein area A₂ is greater than about 0.35 in².

17. The one-piece dry embossing die of claim 12 wherein the cut edge, the punch element substantially flat raised surface and the embossing element substantially flat raised surface are about the same height above the media abutment surface.

18. The one-piece dry embossing die of claim 12 further comprising an aperture formed in the media abutment surface having an aperture wall extending through the die.

19. The one-piece dry embossing die of claim 18 further comprising;

a plurality of apertures formed in the media abutment surface, each of the plurality of apertures having a respective aperture wall extending through the die.

20. The one-piece dry embossing die of claim 12 wherein the body is formed of a unitary piece of material.

21. The one-piece dry embossing die of claim 12 wherein the body is formed of metal.

22. The one-piece dry embossing die of claim 21 wherein the body is formed of an etched metal.

23. The one-piece media embellishing die of claim 12 further comprising:

a press having a press member pressing the media against the media abutment surface and against the blade and against the punch element.

24. A method of embellishing media with a press comprising: placing sheet media against a one-piece embellishing die including a media abutment surface, a die blade extending from the media abutment surface and terminating in a cut edge, a punch element having a protruding member extending from the media abutment surface and terminating in a substantially flat surface and an embossing element having a protruding member extending from the media abutment surface and terminating in a substantially flat surface;

pressing the media against the media abutment surface during a first pressing, the first pressing including:

pressing the media against the punch element forming a first embossment in the media,

pressing the media against the embossing element forming a second embossment in the media, and pressing the media against the die blade cutting the media with the cut edge; and

pressing the media against the media abutment surface during a second pressing, the second pressing including:

pressing the first embossment against the punch element, the punch element protruding member punching through the media at the first embossment,

pressing the second embossment against the second protrusion without punching through the media at the second embossment.

25. The method of claim 24 wherein the first pressing and the second pressing generate the same press forces against the die.

26. The method of claim 24 wherein the first pressing and the second pressing generate the different press forces against the die.

27. The method of claim 24 wherein the one-piece embellishing die further includes an aperture formed in the media abutment surface having an aperture wall extending through the die and the pressing the media against the media abutment surface further includes pressing the media into the aperture forming a debossment in the media.

28. The method of claim 27 further comprising applying embellishing material to the media through the aperture using the aperture wall as a stencil.

29. A one-piece media embellishing die for embossing and die cutting sheet media in a press comprising:

a one-piece body having a media abutment surface, a die blade extending from the media abutment surface and terminating in a cut edge, a punch element having a protruding member extending from the media abutment surface and terminating in a substantially flat surface having a surface area Ai, and an embossing element having a protruding member extending from the media abutment surface and terminating in a substantially flat surface having a surface area A₂, wherein A₂ > Ai and Ai is about 80.0x10^"6 in² to about 0.3 in².